U.S. patent application number 11/209553 was filed with the patent office on 2006-03-02 for cartridge for miniature optical data storage disc.
This patent application is currently assigned to Vmedia Research, Inc.. Invention is credited to Rene D. Kumar Anirudhan, Pk Bala, Gregory Dimitri Volan, Steven B. Volk.
Application Number | 20060048167 11/209553 |
Document ID | / |
Family ID | 38048952 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060048167 |
Kind Code |
A1 |
Volk; Steven B. ; et
al. |
March 2, 2006 |
Cartridge for miniature optical data storage disc
Abstract
A cartridge for an optical data storage disc includes a
monolithic shell and a sheet metal cover plate. The shell includes
lateral walls and a floor that together define a cavity that holds
an optical data storage disc. The cover plate is attached to the
shell, with the cover plate abutting the top surfaces of the
lateral walls of the shell. The optical disc is housed in the disc
cavity, with the data side of the disc facing the cover plate. A
sheet metal shutter is wrapped around an edge of the cartridge and
is slideable between an open position, wherein a portion of the
optical disc is exposed through a shutter window in the cover plate
and a closed position wherein the shutter overlies the shutter
window. The cartridge is very strong and is easy to fabricate. The
use of sheet metal next to the data side of the optical disc allows
the data on the disc to be read or recorded with a very short
wavelength laser.
Inventors: |
Volk; Steven B.; (Boulder,
CO) ; Volan; Gregory Dimitri; (Longmont, CO) ;
Anirudhan; Rene D. Kumar; (Lafayette, CO) ; Bala;
Pk; (Lafayette, CO) |
Correspondence
Address: |
SILICON VALLEY PATENT GROUP LLP
2350 MISSION COLLEGE BOULEVARD
SUITE 360
SANTA CLARA
CA
95054
US
|
Assignee: |
Vmedia Research, Inc.
Boulder
CO
|
Family ID: |
38048952 |
Appl. No.: |
11/209553 |
Filed: |
August 22, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10423097 |
Apr 25, 2003 |
|
|
|
11209553 |
Aug 22, 2005 |
|
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|
Current U.S.
Class: |
720/600 ;
G9B/23.027; G9B/23.033; G9B/23.039 |
Current CPC
Class: |
G11B 23/0315 20130101;
G11B 23/0302 20130101; G11B 23/0326 20130101; G11B 23/0308
20130101; G11B 23/0316 20130101 |
Class at
Publication: |
720/600 |
International
Class: |
G11B 33/02 20060101
G11B033/02 |
Claims
1. A cartridge for an optical data storage disc comprising: a
monolithic plastic shell having a disc cavity, the disc cavity
bounded by a floor and lateral walls, the lateral walls laterally
surrounding the disc cavity; an optical data storage disc located
in the disc cavity; and a sheet metal cover attached to the shell,
the sheet metal cover abutting the top surfaces of the lateral
walls so as to enclose the disc cavity, a shutter window being
formed in the sheet metal cover; and a shutter wrapped around an
edge of the cartridge, the shutter comprising a protective flap
adjacent the cover plate, the shutter slideable along the edge of
the cartridge between an open position wherein a portion of the
optical disc is exposed through the shutter window and a closed
position wherein the protective flap overlies the shutter window to
conceal the optical disc.
2. The cartridge of claim 1 wherein the plastic shell comprises a
plurality of plastic assembly posts, each of the assembly posts
projecting through a hole in the sheet metal cover, a mushroom cap
being formed at an end of each of the assembly posts to hold the
sheet metal cover against the plastic shell.
3. The cartridge of claim 2 wherein a recess is formed around each
of the holes, each mushroom cap being formed in one of the
recesses.
4. The cartridge of claim 1 wherein a data side of the optical data
storage disc faces the sheet metal cover.
5. The cartridge of claim 4 wherein an annular raised rim is formed
around a center hole on the data side of the optical data storage
disc.
6. The cartridge of claim 4 wherein a non-data side of the optical
data storage disc faces a floor of the shell, a magnetic retainer
ring being attached to the non-data side of the disc concentric
with a central hole of the disc.
7. The cartridge of claim 1 wherein the shell measures about 36
mm.times.36 mm.times.3 mm.
8. The cartridge of claim 1 wherein the sheet metal cover is
substantially planar.
59. The cartridge of claim 8 wherein the shutter comprises a
clamping flap and an edge wall, the edge wall connecting the
protective flap and the clamping flap.
10. The cartridge of claim 9 wherein the clamping flap is disposed
in a shallow recess formed in the sheet metal cover.
11. The cartridge of claim 10 wherein the sheet metal cover is
attached to the plastic shell by a plurality of plastic assembly
posts, each of the assembly posts projecting through a hole in the
sheet metal cover, a mushroom cap being formed at an end of each of
the assembly posts to hold the sheet metal cover against the
plastic shell, an annular recess being formed around each of the
holes.
12. The cartridge of claim 11 wherein the sheet metal cover
comprises a plurality of lateral edges, each of the edges being
disposed in a recess in one of the lateral walls of the plastic
shell.
13. A method of fabricating a cartridge for an optical data storage
disc comprising: providing a plastic shell, the plastic shell
having a disc cavity, the disc cavity bounded by a floor and
lateral walls, the lateral walls laterally surrounding the disc
cavity, the plastic shell further comprising a plurality of plastic
assembly posts; providing a sheet metal cover sheet having a
plurality of holes; placing an optical data storage disc in the
disc cavity; placing the sheet metal cover sheet adjacent the
plastic shell so as to enclose the optical data storage disc in the
disc cavity, each of the assembly posts projecting through one of
the holes; heating an end portion of each of the assembly posts to
form a cap which holds the sheet metal cover against the plastic
shell.
14. The method of claim 13 comprising fitting a shutter around an
edge of the shell.
15. The method of claim 13 wherein heating an end portion of each
of the assembly posts comprising heating with an iron.
16. The method of claim 13 wherein heating an end portion of each
of the assembly posts comprising heating with an ultrasonic
tool.
17. The method of claim 13 comprising gluing a magnetic retainer
ring to the optical data storage disc.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application
Ser. No. 10/423,097, filed Apr. 25, 2003, which is incorporated
herein by reference in its entirety. This application is related to
application Ser. No. 10/423,701, filed Apr. 25, 2003, which is also
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to high-volume data storage and, in
particular, to a cartridge for an optical data storage disc that is
compatible with an industry-standard memory card slot in a portable
computing device.
BACKGROUND OF THE INVENTION
[0003] Consumer entertainment technologies are moving towards high
resolution color displays for mobile entertainment. Increasingly,
consumers want to take their entertainment with them. Cross-country
travelers and cross-town commuters are eagerly pursuing gaming,
music and video entertainment activities on cell phones, personal
digital assistants (PDAs) and portable computers. At present,
however, the entertainment experience is limited, even primitive,
compared to what consumers have come to expect from their game
consoles, home theaters and DVD-equipped computers.
[0004] The main problem is data storage. The fact is that
sophisticated digital entertainment is data-intensive, and it is
growing more so every day. Traditional small "form factor,"
portable media such as CompactFlash.RTM. cards, SD flash cards,
Memory Stick.TM. and other solid state memory devices simply cannot
deliver the capacity and price per megabyte required for a
high-quality entertainment experience. Recording content onto solid
state memory cards in high volume is expensive and impractical, and
securing that content effectively is very difficult.
[0005] While some experts predict that broadband Internet access
will deliver high-quality games and movies to mobile consumer
electronics devices, there are significant barriers to success.
Cell phone networks are designed to transmit voice communications
and are simply not efficient for high-capacity data transmission.
Cell connections are not capable of the required speeds and are
notoriously unreliable, with frequent dead zones and dropped
connections. While games are being delivered to cell phones
currently, the quality of game play and the game environment cannot
begin to approach that of a console.
[0006] WiFi, or 802.11, wireless is designed for data transmission,
and the growing of WiFi hotspots looks attractive on the surface
for delivering large amounts of data to mobile devices. Internet
access and email application for multiple users are easily
accommodated by WiFi. Nonetheless, managing streaming and
interactive content such as multiplayer games and high-quality
video or movies for thousands, if not millions, of users
simultaneously will be challenging for any network. Security is
also a problem for WiFi, leaving content providers open to
potential pirating activities.
[0007] Moreover, the data storage problem would still exist. For
any sort of networked delivery system to be viable, mobile consumer
devices will have to embed significant amounts of storage to hold
large, downloaded game and movie files, and to track a player's
progress within the game. Perhaps the most significant problem for
networked content delivery is cost. It has been estimated that it
can cost more than $30 to send a DVD-quality film over the
Internet.
[0008] Disc-based distribution costs are far lower. Even more
compelling is the fact that consumers have consistently
demonstrated their preference for purchasing high-value content on
discs, as evidenced by the recent upswing in DVD sales.
[0009] Clearly, the mobile entertainment industry needs an
economical, small form factor, secure storage technology to meet
the growing demand for a portable, high-quality entertainment
experience. In addition, it is anticipated that a storage device
capable of holding large amounts of data would find application in
other areas, such as in portable computers used in connection with
the homeland security effort.
SUMMARY OF THE INVENTION
[0010] A first embodiment of a cartridge in accordance with this
invention includes a sheet metal sheath and an insert, preferably
made of plastic. The sheath is made from a sheet of sheet metal
that is preferably folded back on itself to form wall portions on
opposite sides of a bend area. An insert, preferably made of
plastic, is inserted into the sheath, and the wall portions are
attached to each other, for example by spot welding, to form a
small, structurally sound unit. The insert has an opening into
which a data storage disc is placed. The disc is preferably hubless
and accessible by a spindle through an opening in the sheath. One
of the wall portions has a window which allows access to the data
area of the disc and a shutter which covers the window and protects
the disc when the cartridge is not inside a disc drive.
[0011] Using a metal sheath allows the cartridge assembly to be
made very thin (e.g., 2.8 mm or less thick) without compromising
its structural integrity. With this structure, the cartridge can
provide large amounts of data (e.g., 2 Gbytes or more) to a small,
industry-standard slot that is generally designed for use with a
data card. One example is the CompactFlash.RTM. slot that is used
in many PDAs and other small computers. Spot-welding the wall
portions to each other can be performed very quickly without
adhesives or the associated cure time.
[0012] Ideally, the cartridge of this invention is used with a disc
drive of the type described in the above-referenced application
Ser. No. 10/423,701.
[0013] In a second embodiment of this invention, the cartridge
comprises a monolithic shell formed to define a disc cavity. The
shell is preferably made of plastic. The disc cavity is bounded by
a floor and lateral walls, and the lateral walls laterally enclose
the disc cavity. An optical data storage disc is located in the
disc cavity. A sheet metal cover plate abuts the top surfaces of
the lateral walls. A shutter window is formed in the cover plate,
and a sheet metal shutter is wrapped around an edge of the
cartridge. The shutter includes a protective flap adjacent the
cover plate. The shutter is slideable along the edge of the
cartridge between an open position wherein a portion of the optical
disc is exposed through the shutter window and a closed position
wherein the protective flap overlies the shutter window to conceal
the optical disc.
[0014] Thus, one principal surface and the edge of the disc are
enclosed by the shell and the other principal surface of the disc
is covered by the cover plate.
[0015] The disc is housed in the disc cavity with its data side
facing the cover plate and its non-data side facing the shell. The
shutter window formed in the cover plate allows a portion of the
data area and the center hole of the disc to be exposed. The
shutter includes a clamping flap that joined to the protective flap
by an edge wall. The clamping flap is located adjacent the
shell.
[0016] The disc preferably has a magnetic retainer ring bonded to
its non-data side around its center hole. The disc is clamped to
the shaft of a spindle motor in a disc drive by means of the
magnetic retainer.
[0017] A plastic latch, housed in a latch cavity in the shell,
holds the shutter in a position which covers the window in the
cover plate when the cartridge is not in a disc drive.
[0018] When the cartridge is inserted into a disc drive, a picker
arm in the disc drive releases the latch and allows the shutter to
open, exposing the data area and center hole of the disc.
[0019] A cartridge of the second embodiment is relatively
inexpensive to manufacture and provides a structurally robust
enclosure for protecting an optical disc. The use of a relatively
thin sheet metal cover sheet on the data side of the disc allows
the optical pickup unit (OPU) in a disc drive to read data from the
disc using very short wavelength radiation, such as a 405 nm blue
laser light.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIGS. 1A and 1B are perspective views of the top and bottom,
respectively, of the cartridge of this invention.
[0021] FIGS. 2A and 2B are plan views of the top and bottom,
respectively, of the cartridge of this invention.
[0022] FIG. 3 is an exploded view of the cartridge.
[0023] FIGS. 4A and 4B are views of the plastic insert and shutter
showing the shutter in the closed and open positions,
respectively.
[0024] FIG. 5 is a detailed view of the latch.
[0025] FIG. 6 is a detailed view of the shutter.
[0026] FIGS. 7A and 7B are plan views of top and bottom,
respectively, of the metal sheath.
[0027] FIG. 8 is a top view of the plastic insert showing the disc
and the latch.
[0028] FIG. 9 is a cross-sectional view of the cartridge taken at
section 9-9 shown in FIG. 1B.
[0029] FIGS. 10A and 10B show the location of the retention recess
on the cartridge.
[0030] FIGS. 11A and 11B are two exploded views of a second
embodiment of a cartridge according to the invention.
[0031] FIGS. 12A and 12B illustrate the plastic shell in the second
embodiment.
[0032] FIG. 12C illustrates a portion of the shell.
[0033] FIG. 12D is a cross-sectional view taken at section line
12D-12D in FIG. 12B.
[0034] FIG. 13 shows a top view of the cover plate in the second
embodiment.
[0035] FIG. 14A is a cross-sectional view taken at section line
14A-14A in FIG. 13.
[0036] FIG. 14B is a cross-sectional view taken at section line
14B-14B in FIG. 13.
[0037] FIGS. 15A-15D illustrate the structure of the shutter in the
second embodiment.
[0038] FIG. 16 is a cross-sectional view of the disc assembly in
the second embodiment.
[0039] FIGS. 17A and 17B are top views of the disc assembly from
the data side and the non-data side, respectively.
[0040] FIGS. 18A and 18B are cross-sectional views of the center
region and the edge region, respectively, of the optical disc.
[0041] FIG. 19A is a top view of the magnetic retainer ring.
[0042] FIG. 19B is a perspective view of the magnetic retainer
ring.
[0043] FIG. 19C is a cross-sectional view along a diameter of the
magnetic retainer ring.
[0044] FIGS. 20A and 20C are top and bottom views, respectively, of
the latch in the second embodiment.
[0045] FIG. 20B is a side view of the latch.
[0046] FIG. 20D shows the latch positioned in the latch cavity.
[0047] FIG. 20E shows the hook and release cam projecting into the
shutter tracking groove.
[0048] FIG. 21 is a cross-sectional view of the thick perimeter
wall taken at section line 21-21 shown in FIG. 12A.
[0049] FIG. 22 is a general view of a cartridge according to the
invention being inserted into a cartridge tray in a disc drive.
[0050] FIG. 23A is a top view of a portion of a cartridge tray,
showing the mechanism for releasing the shutter as the cartridge is
inserted into cartridge tray.
[0051] FIGS. 23B and 23C are perspective views of the same
structure shown in FIG. 23A.
[0052] FIGS. 24-26 are views showing how a spindle motor shaft
engages the center hole of disc assembly.
[0053] FIG. 27A shows the latch hook contacting the latch tab of
the shutter as the shutter closes.
[0054] FIG. 27B shows the relative positions of the latch and the
latch tab when the shutter is fully closed.
[0055] FIG. 28A shows the hook and the release cam retracted out of
the shutter tracking groove when the release cam has been contacted
by a feature of the disc drive as the cartridge is being inserted
into the drive.
[0056] FIG. 28B shows how the hook of the latch is released from
the latch tab in the condition shown in FIG. 28A.
DESCRIPTION OF THE INVENTION
[0057] FIGS. 1A and 1B show perspective views of a cartridge 10
according to this invention. Included in both views are an insert
102, which is preferably made of plastic, and a sheath 104, which
is made of sheet metal, preferably stainless steel. Insert 102 will
be referred to as a "plastic insert" herein, although it will be
understood that insert 102 could be made of other materials, such
as metals, ceramics, linen phenolic, wood, composite materials,
compressed paper or other fibers. FIG. 1A shows the top side of
cartridge 10, and FIG. 1B shows the bottom side of cartridge 10.
FIGS. 2A and 2B are top and bottom plan views of cartridge 10,
respectively. Also visible in these views are a shutter opening
106, a shutter 108, and a spindle opening 110. As shown in FIG. 2A,
a recess 193 is formed in cartridge 10. Recess 193 interacts with a
mechanism on the drive to retain cartridge 10 in the drive after it
has been inserted into the drive. Recess 193 is also shown in FIGS.
10A and 10B.
[0058] FIG. 3 shows an exploded view of cartridge 10, viewed from
the bottom side. As shown, sheet metal sheath 104 is preferably
made from a single piece of sheet metal that is folded back on
itself in a bend area 122, forming a bottom wall portion 104B and a
top wall portion 104T on the opposite sides of bend area 122.
Plastic insert 102 is inserted into sheath 104 in the direction
indicated by the arrows 128. Plastic insert 102 includes an opening
124 wherein an optical data storage disc 116 is enclosed, and one
edge of plastic insert 102 has a gap 126 that leads to opening 124.
When cartridge 10 is fully assembled, gap 126 of plastic insert 102
is adjacent the bend area 122 of sheath 104. Three tabs 130 (of
which only two are visible) project radially inward from the edge
of opening 124, which is in the shape of a circular arc. Disc 116
rests on tabs 130 during the assembly of cartridge 10, before
plastic insert 102 has been inserted into sheath 104. In another
embodiment, the metal sheath includes wall portions that are
separate from each other.
[0059] Shutter 108 fits adjacent to top wall portion 104T and moves
between an open position, wherein shutter opening 106 is exposed,
and a closed position, wherein shutter opening 106 is closed.
Shutter 108 slides in a recessed area 105 of wall portion 104T,
shown in FIG. 1A, that is formed by stamping the sheet metal. The
inside surface of shutter 108 may be coated with PTFE or another
coating to reduce friction and wear. In moving between the open and
closed positions, shutter 108 slides on a rail 132 that is formed
in plastic insert 102. A sliding portion 134 of shutter 108 slides
on rail 132. A tab 136 at a cantilevered end of shutter 108 slides
under a metal strip 118, preferably stainless steel, which is
welded to the face of top wall portion 104T.
[0060] Shutter 108 is locked in the closed position by a latch 114,
which fits into a latch recess 120 formed in plastic insert 102. A
rectangular window 140 in shutter 108 is designed to engage a
feature of an external disc drive to pull shutter 108 from the
closed position to the open position when cartridge 10 is inserted
into the disc drive. In this embodiment, cartridge 10 is inserted
into a disc drive in the direction of arrow 142, and a pair of
knurled areas 144 are provided on plastic insert 102 to assist the
user in manually gripping cartridge 10. The second knurled area
144, located near the upper corner of plastic insert 102, is not
visible in FIG. 3.
[0061] FIGS. 4A and 4B show plastic insert 102 and shutter 108,
with shutter 108 in the open and closed positions, respectively.
FIGS. 5 and 6 are detailed views of latch 114 and shutter 108,
respectively. As shown in FIGS. 4A and 4B, latch 114 rests in latch
recess 120. Latch 114 is preferably made of molded plastic,
preferably nylon. As shown in FIGS. 4A, 4B and 5, latch 114 has a
cylindrical surface 148 which contacts a corresponding cylindrical
wall of recess 120, thereby allowing a main body 150 of latch 114
to rotate within recess 120 about a vertical axis defined by
cylindrical surface 148. Latch 114 also contains a spring arm 152,
which is made thin enough to flex and which is angled with respect
to the main body 150 such that spring arm 152 flexes slightly in
the direction of arrow 154 when latch 114 is placed in recess 120,
thereby maintaining latch 114 in the extended position shown in
FIGS. 4A and 4B. With this structure, there is no need to connect
latch 114 to plastic insert 102 and/or sheath 104 by means of a
rotary shaft or pin. This is a significant feature when the parts
must be very small.
[0062] Latch 114 also contains a notch 156 which mates with a tab
158 of shutter 108 when shutter 108 is in the closed position. When
shutter 108 is closed, the spring force provided by spring arm 152
rotates main body 150 of latch 114 such that tab 158 remains in
engagement with notch 156. When shutter 108 is to be opened,
typically by inserting cartridge 10 into a disc drive, an external
feature of the disc drive (not shown) slides against a ramp 160,
thereby opposing the force of spring arm 152 and forcing main body
150 to rotate in such a way the notch 156 retracts into plastic
insert 102 and is disengaged from tab 158. When notch 156 and tab
158 have been separated, an external feature (not shown) engages
window 140, moving shutter 108 from the closed position to the open
position. When cartridge 10 is removed from the disc drive, the
external feature slides shutter 108 from the open position to the
closed position, and tab 158 slides on a ramp 162 (see FIG. 5),
again retracting latch 114 until tab 158 clears the ramp 162 and
again rests in notch 156.
[0063] FIG. 8 is a top view of cartridge 10 with the sheet metal
sheath 104 removed, showing the position of latch 114 in recess 120
as well as the location of the axis of rotation 190 of latch 114.
Also shown in FIG. 8 is the engagement of notch 156 and tab
158.
[0064] It will be understood that there are numerous other ways of
providing a shutter locking function. This invention is not limited
to the example described above, but rather may employ a wide
variety of alternative techniques for controlling the shutter.
[0065] Referring again to FIG. 3, sheet metal sheath 104 contains
metal tabs 164A and 166A, which project from top wall portion 104T.
When sheath 104 is in a relaxed condition, the ends of tabs 164A
and 166A abut bottom wall portion 104B. Referring to FIG. 4A, slots
164B and 166B are formed in plastic insert 102, with the dimensions
of tab 164A being approximately the same as the dimensions of slot
164B, and the dimensions of tab 166A being approximately the same
as the dimensions of slot 166B. In short, tabs 164A and 166A fit
snuggly into slots 164B and 166B, respectively.
[0066] Prior to the assembly of plastic insert 102 and sheet metal
sheath 104, disc 116 is placed in opening 124, resting on tabs 130.
The wall portions 104T and 104B are then separated slightly, and
plastic insert 102 is inserted into sheath 104, until tab 164A is
in slot 164B and tab 166A is in slot 166B. Since sheath 104 is
preferably made of a resilient material such as stainless steel,
wall portions 104T and 104B can flex sufficiently to allow this to
take place and then return to their original shape. At this point,
the ends of tabs 164A and 166A are spot-welded to wall portion
104B. This produces a very rigid structure.
[0067] To increase the strength of cartridge 10, sheath 104 also
contains tabs 168A and 170A, which extend laterally from bend area
122. Tab 168A is shown in FIG. 3, and it will be understood that
tab 170A extends in a similar manner at the opposite end of bend
area 122. Referring to FIG. 4A, plastic insert has niches 168B and
170B formed on the opposite sides of gap 126. As plastic insert 102
is inserted into sheath 104, as described above, tab 168A fits into
niche 168B, and tab 170A fits into niche 170B. This arrangement
provides additional structural stability in the vicinity of gap
126.
[0068] Disc 116 is designed to operate with a spindle hub having a
barbed, snap-fit retainer similar to those employed in ordinary CD
drives. Thus, as shown in FIG. 3, disc 116 has a central hole 116A
but does not have a hub. When cartridge 10 has been fully
assembled, disc 116 is supported by raised rings 180 and 182, shown
in FIGS. 7A and 7B, that are formed on the inside surfaces of wall
portions 104T and 104B, respectively. Raised rings 180 and 182 are
embossed in the sheet metal. In one embodiment raised rings 180 and
182 are 0.35 mm high. FIG. 9 is a cross-sectional view of cartridge
10 showing the locations of raised rings 180 and 182. As indicated,
raised ring 180 is located at the circumference of spindle opening
110. Also shown in FIG. 9 is a paper label 192 that fits in a
stamped recess in the bottom wall portion of 104B of sheet metal
sheath 104. This is sometimes referred to as the "label side" of
cartridge 10.
[0069] In one embodiment, cartridge 10 is designed to fit into a
disc drive that fits into a CompactFlash.RTM. slot in a PDA, for
example. The thickness of such a cartridge could be targeted at 2.0
mm. Disc 116 could be 32 mm in diameter and 0.7 mm thick, leaving
about 1.3 mm for remainder of the cartridge. Top wall portion 104T
and shutter 108 are on one side of disc 116, and bottom wall
portion 104B is on the other side of disc 116. If sheath 104 and
shutter 108 are made of a sheet of stainless steel 0.15 mm thick,
the combined thicknesses of these components would account for 0.45
mm. In addition, there might be a clearance of about 0.025 mm
between the shutter 108 and top wall portion 104T, and a label
0.100 mm thick might be placed on one side of the cartridge,
increasing the total to 0.575 mm. This would leave 0.725 mm
(1.3-0.575) for the clearance between disc 116 and the inside
surfaces of wall portions 104T and 104B, or 0.3625 mm on each side
of disc 116. Assuming a vertical disc runout of .+-.0.05 mm, a
clearance of 0.3125 mm remains for the feature size and position
tolerances and any runout caused by the spindle and disc-to-spindle
interface.
[0070] By comparison, if the top and bottom walls of the cartridge
were made of plastic, a stable structure would require a minimum
thickness on the order of 0.32 mm, instead of 0.15 mm for the sheet
metal (the shutter thickness would remain the same). In addition,
0.07 mm would have to be allowed for variations in the flatness of
the plastic walls. Thus the 0.3125 mm clearance on each side of the
disc would be reduced to 0.0725 mm (0.3125-((0.32-0.15)+0.07))).
This is too small to accommodate the remaining variables such as
runout caused by the spindle.
[0071] An alternative embodiment according to the invention is
shown in FIGS. 11-15, which illustrate a cartridge 20.
[0072] FIGS. 11A and 11B are two exploded views of cartridge 20,
FIG. 11A being taken from above, FIG. 11B being taken from below.
Cartridge 20 includes a shell 200, typically made of plastic, a
cover plate 202, made of sheet metal, a shutter 204, an optical
data storage disc assembly 206, and a latch 208.
[0073] The detailed structure and method of assembling cartridge 20
will now be described.
[0074] FIGS. 12A and 12B illustrate shell 200 from the outside and
inside, respectively. Shell 200 may be made of lens grade
polycarbonate and may be manufactured by a standard injection
molding process. In one embodiment the lateral dimensions of shell
200 are approximately 36 mm.times.36 mm, and shell 200 is
approximately 3 mm thick. Shell 200 has a leading edge 217 and a
trailing edge 218 Trailing edge 218 is arc-shaped (e.g., radius
.apprxeq.78 mm); leading edge 217 and the side edges are generally
linear.
[0075] As shown in FIG. 12A, the outside of shell 200 has shallow
recesses 214 and 216, which may be recessed by 0.2 mm with respect
to the surrounding portions of shell 200. As described below, a
portion of shutter 204 slides in recess 214, and recess 216 can be
used to hold printed material, such as a movie label. Alignment
holes 222A and 222B fit over corresponding alignment posts (not
shown) in the disc drive to assure that cartridge 20 is accurately
positioned in the drive. Near the trailing edge 218 are three
longitudinal grooves 219, approximately 0.4 mm wide and separated
by 0.6 mm, to assist the user in gripping cartridge 20 when
inserting it into a disc drive.
[0076] As shown in FIG. 12B, the inside of shell 200 includes a
floor 201 and a plurality of lateral walls, including four inside
walls 211A-211D and four perimeter walls 212A-212D. Each of
perimeter walls 212A-212D runs along one side of the perimeter of
shell 200. Each of inside walls 211A-211D is formed generally in
the shape of a circular arc. Floor 201, inside walls 211A-211D and
portions of perimeter walls 212A-212D together define a generally
circular disc cavity 210, which is used to hold disc assembly 206.
As explained further below, viewed from the inside of shell 200,
perimeter wall 212D is thicker than perimeter walls 212A-212C. At
one corner of shell 200, inside wall 211A and portions of perimeter
walls 212A and 212D form a latch cavity 207, which is used to hold
latch 208. Five assembly posts 213, located in latch cavity 207 and
in three cavities formed by inside walls 211B-211D and perimeter
walls 212A-212D, are used to attach cover plate 202 to shell
200.
[0077] As is apparent from FIGS. 12A and 12B shell 200 is
preferably monolithic, i.e., shell 200 is preferably formed of a
single integral piece of material. Shell 200 is preferably made of
plastic but other materials such as metal could also be used to
fabricate shell 200.
[0078] FIG. 12C is a detailed view of the area around leading edge
217 of shell 200. A recess 209 is formed in perimeter wall 212B.
Recess 209 interacts with a pawl (not shown) in the disc drive to
retain cartridge 20 in the drive when it is fully loaded.
[0079] FIG. 12D is a cross-sectional view of the assembly post 213
in latch cavity 207, taken at section line 12D-12D in FIG. 12B. As
shown, assembly post 213 extends upward to a level slightly above
inside wall 211A and perimeter wall 212A. As described below, this
additional material in assembly posts 213 is melted to form a
mushroom cap in order to attach cover plate 202 to shell 200.
[0080] FIG. 13 shows a top view of cover plate 202. Cover plate 202
can be made of a stainless steel sheet 0.15 mm thick. The stainless
steel sheet is stamped to form a recess 230 and a shutter window
232 within recess 230. Recess 230 can be recessed 0.2 mm, for
example, with respect to the surrounding portions of cover plate
202. As described below, a portion of shutter 204 slides back and
forth in recess 230 to open and close window 232. This movement
alternately protects disc assembly 206 from damage and allows data
stored on disc assembly 206 to be read by an external optical
pickup unit (not shown).
[0081] Near the corners of cover plate 202 are five recessed holes
234. FIGS. 14A and 14B are cross-sectional views of two of recessed
holes 234, taken at section lines 14A-14A and 14B-14B,
respectively, in FIG. 13. As shown, the edge of recessed hole 234
is recessed (e.g., by 0.15 mm) with respect to the surrounding
surface of cover plate 202.
[0082] Cover plate 202 is planar except for recess 230 and the
recesses around holes 234. In other embodiments, recess 230 and/or
the recesses around holes 234 may be omitted.
[0083] Notches 238A and 238B in cover plate 202 are aligned with
alignment holes 222A and 222B in shell 200 to accommodate the
alignment posts (not shown) in the disc drive.
[0084] FIGS. 15A-15D illustrate the structure of shutter 204. As is
evident from FIG. 15C, shutter 204 is U-shaped. Shutter 204 may be
made from a sheet of stainless steel 0.13 mm thick, for example.
When cartridge 20 is assembled, shutter 204 essentially wraps
around one edge of cartridge 20 and slides along the edge of
cartridge 20 to alternately open and close a shutter window in
cover plate 202. As shown in FIG. 15C, shutter 204 includes a
protective flap 224 and a clamping flap 226, which are connected
together by an edge wall 228. FIG. 15A shows shutter 204 from the
side of protective flap 224; FIG. 15B shows shutter 204 from the
side of clamping flap 226; and FIG. 15D shows shutter 204 from the
side of edge wall 228. As shown in FIG. 15B, clamping flap 226 is
stamped to form tracking tabs 226A and 226B and a latch tab 226C.
Tracking tabs 226A and 226B may have a width equal to 1.25 mm and
latch tab 226C may have a width equal to 0.7 mm, for example. The
length of tracking tabs 226A and 226B and latch tab 226C can be
0.43 mm. Latch tab 226C is slanted at an angle .alpha. of about
20.degree. in relation to edge wall 228.
[0085] As shown in FIG. 15D, an opening 229 is formed in edge wall
228. Opening 229 engages a feature in the disc drive to assist in
opening and closing shutter 204 as cartridge 20 is inserted into
and withdrawn from the disc drive.
[0086] FIG. 16 shows a cross-sectional view of disc assembly 206,
which includes an optical disc 240 and an annular magnetic retainer
ring 242. FIGS. 17A and 17B are top views of disc 240 from its data
side and the non-data side, respectively. Referring to FIG. 16, the
non-data side of optical disc 240 is shown facing upward and the
data side of optical disc 240 is shown facing downward. Optical
disc 240 may be 32 mm in diameter and 0.55 mm thick and has a
center hole 244 which may be 4.010-4.022 mm in diameter. Magnetic
retainer ring 242 is glued to the non-data side of optical disc 240
concentric with center hole 244.
[0087] Referring to FIG. 17A, data area 250 of optical disc 240 is
shown. The inner circumference of data area 250 may have a radius
of 6.88 mm and the outer circumference of data area 250 may have a
radius of 14.8 mm. A bar code area/inner radius graphics (BCA/IRG)
area 256 extends from a radius of 5 mm to a radius of 5.8 mm.
[0088] FIG. 18A is a cross-sectional view of optical disc 240 in
the area around center hole 244. On the non-data (top) side, a
shallow recess 245, which may be 0.05 mm deep, is formed in the
area where magnetic retainer ring 242 will be attached to optical
disc 240 by gluing. A circular moat 246, which may be 0.2 mm deep
and 1 mm wide, is formed to catch any glue that may flow inward and
thereby prevent the glue from entering center hole 244. Moat 246
may be 6 mm in diameter.
[0089] On the data (bottom) side of optical disc 240, a circular
raised rim 248 is formed concentric with center hole 244, to
prevent data area 250 of optical disc 240 from coming into contact
with cover plate 202 when disc assembly 206 is enclosed in disc
cavity 210. Rim 248 may be 0.25 high, 1 mm wide and 9 mm in
diameter. Raised rim 248 is also useful in the disc cover layer
manufacturing process, since it prevents the liquid lacquer used in
the cover layer spin coating process from flowing into center hole
244. When disc assembly 206 is in a static position, with its
non-data side resting on floor 201 of disc cavity 210, the
clearance between raised rim 248 and the inside surface of cover
plate 202 is about 0.35 mm.
[0090] Just outside of rim 248 is a stamper holder feature 252.
Recess 245, moat 246, rim 248 and stamper holder feature 252 are
formed when optical disc 240 is molded. Optical disc 240 is
preferably made of polycarbonate and is formed by a known injection
molding process. The standard molding process used in the
manufacture of DVD discs may be used to manufacture optical disc
240.
[0091] The thickness of cartridge 20 could be targeted at 2.8 mm.
Optical disc 240 could be 32 mm in diameter and have a maximum
thickness (including magnetic retainer ring 242) of 0.9 mm, leaving
about 1.9 mm for the remainder of cartridge 20.
[0092] FIG. 18B is a cross-sectional view near the edge of optical
disc 240. As shown, the edge of optical disc 240 is formed with a
draft angle d of 5-7 degrees to allow the disc to be ejected from
the mold without deforming the molded disc.
[0093] FIGS. 19A, 19B and 19C are views of magnetic retainer ring
242. The center hole of magnetic retainer ring 242 may have a
diameter of 4.5 mm and the outer circumference of magnetic retainer
ring 242 may have a diameter of 9.2 mm. Magnetic retainer ring 242
may be formed of a 0.2 mm thick sheet of stainless steel 430 or
another magnetic metal.
[0094] Magnetic retainer ring 242 may be attached to optical disc
240 by supporting magnetic retainer ring 242 on a mounting post and
placing adhesive dots of an ultraviolet (UV) curable adhesive such
as Dymax 3013-T onto magnetic retainer ring 242. Optical disc 240
is placed on magnetic retainer ring 242 with the data side facing
upward and with magnetic retainer ring 242 fitted into recess 245.
A vertical top load (e.g., 5-7 oz) is placed on optical disc 240
and UV light is directed through the vertical top load and center
hole 244 to cure the adhesive. The vertical top load is annular
with a 5-8 mm through hole to allow a UV light guide to be
used.
[0095] FIGS. 20A and 20C are top and bottom views, respectively, of
latch 208. FIG. 20B is a side view of latch 208. Latch 208 can be
made of a flexible plastic such as polypropylene. Latch 208
includes arm segments 256, 258 and 260, each of which can be formed
of a strip that is 1.5 mm wide and 0.5 mm thick. Arm segment 258
may be 3.4 mm long and arm segment 260 may be 7.2 mm long. The
angle a between arm segments 256 and 258 may be 36.degree.; the
angle b between arm segments 258 and 260 may be 105.degree.. An arc
segment 261 is located at an end of arm segment 256.
[0096] A hook 262 and a release cam 264 extend from one side of arm
segment 260. Hook 262 has a cam surface 265 on one side and a
gripping surface 267 on the opposite side. Cam surface 265 can be
angled at 105.degree. with respect to the longitudinal direction of
arm segment 260, and gripping surface 267 is close to perpendicular
to the longitudinal direction of arm segment 260. Release cam 264
has a leading edge 266 and a trailing edge 268. Leading edge 266 is
angled at about 75.degree. with respect to the longitudinal
direction of arm segment 260. A notch 263 is formed between hook
262 and release cam 264. As can be seen from FIG. 20B, hook 262 and
release cam 264 are not as thick as arm segments 256, 258 and
260.
[0097] FIG. 20D shows how latch 208 is positioned in latch cavity
207 (see also FIG. 12B). Arc segment 261 and arm segments 256 and
258 enclose one of assembly posts 213 and arm segment 258 rests
against perimeter wall 212A. Hook 262 and release cam 264 extend
through a window in perimeter wall 212D into a shutter tracking
groove 220, which is formed in perimeter wall 212D on the opposite
side of shell 200. As assembled in latch cavity 207, latch 208 is
in a flexed condition. FIG. 20E is a more detailed view of hook 262
and release cam 264 projecting into shutter tracking groove
220.
[0098] Cartridge 20 is assembled by placing latch 208 into cavity
207, placing disc assembly 206 into disc cavity 210, attaching
cover plate 202 to shell 200 using assembly posts 213, and affixing
shutter 204 on the outside of cartridge 200. The use of a
monolithic shell and a cover plate which is attached to one side of
the shell greatly simplifies the fabrication of the cartridge.
These steps will now be described in greater detail.
[0099] Initially latch 208 is placed into latch cavity 207 in the
manner shown in FIG. 20D, with arc segment 261 and arm segments 256
and 258 around the assembly post 213 that is located in latch
cavity 207. Arm segment 256 abuts inside wall 211A, arm segment 258
abuts perimeter wall 212A, and arm segment 260 abuts perimeter wall
212D. The operation of latch 208 is described below.
[0100] Next, disc assembly 206 is placed in disc cavity 210, with
the data side facing upward. Retainer ring 242 rests on the floor
201 of disc cavity 210. The clearance between the outside edge of
optical disc 240 and inside walls 211A-211D can be 1.05 mm.
[0101] With latch 208 in latch cavity 207 and disc assembly 206 in
disc cavity 210, cover plate 202 is placed on top surfaces of
inside walls 211A-211D and perimeter walls 212A-212D, closing latch
cavity 207 and disc cavity 210. Preferably, the lateral dimensions
of cover plate 202 are slightly less than the lateral dimensions of
shell 200, and a shallow recess is formed on the inside edges of
the top surfaces of perimeter walls 212A-212D. Cover plate 202 is
seated in this recess. Assembly posts 213 are positioned so as to
protrude through recessed holes 234 of cover plate 202 by
approximately 0.2 mm. A soldering iron or heat staking tool is then
used to melt the plastic tips of assembly posts 213 and thereby
form mushroom-shaped caps above recessed holes 234. Thus cover
plate 202 is attached to shell 200 by mushroom caps on the tips of
assembly posts 213. The melted plastic may be retained within the
recesses around holes 234 to provide a substantially flat exterior
surface of cartridge 20 on the side of cover plate 202.
[0102] The final step of the assembly process is to mount shutter
204 on the outside of shell 200 and cover plate 202. Since shutter
204 is made of a resilient sheet metal, protective flap 224 and
clamping flap 226 can be separated slightly without permanently
deforming shutter 204. Edge wall 228 of shutter 204 is made just
wide enough to fit around the edge of shell 200. Shutter 204 is
mounted with protective flap 224 within recess 230 of cover plate
202 and clamping flap within recess 214 of shell 200.
[0103] Referring back to FIG. 12A, shutter tracking groove 220
begins at leading edge 217 and extends part of the distance to
trailing edge 218 of shell 220. Shutter tracking groove 220 is
formed in perimeter wall 212D, and as noted above, perimeter wall
212D is made thicker than perimeter walls 212A-212C to accommodate
groove 220. FIG. 21 is a cross-sectional view of perimeter wall
212D taken at section line 21-21 shown in FIG. 12A with shutter 204
in place. Shutter 204 is mounted such that tracking tabs 226A and
226B and latch tab 226C are free to slide in shutter tracking
groove 220. Tracking tabs 226A and 226B are formed in a location on
shutter 204 which allows shutter 204 to slide freely along the edge
of shell 200, with minimal racking or "sloppiness."
[0104] With tracking tabs 226A and 226B and latch tab 226C inside
groove 220, shutter 204 is mounted onto cartridge 20. As shutter
204 slides back and forth along groove 220, protective flap slides
in recess 230 of cover plate 202, alternately opening and closing
window 232. When window 232 is open, center hole 244 and a radial
section of data area 250 are exposed, allowing center hole 244 to
be engaged by a spindle motor and data to be read from data area
250. Similarly, as shutter 204 slides back and forth, clamping flap
226 slides back and forth in recess 214 of shell 200.
[0105] As described above, a window is formed in the side of groove
220 that separates groove 220 from latch cavity 207. The window
extends only part of the way up from the floor 201 of shell 200.
Hook 262 and release cam 264 protrude through this window into
groove 220. As shown in FIG. 20B, hook 262 and release cam 264 do
not extend across the entire thickness of latch 208. This allows
hook 262 and release cam 264 to extend through the window and helps
to securely position latch 208 within latch cavity 207.
[0106] To complete the mounting of shutter 204, shutter 204 is slid
along the edge of shell 200 in the direction of latch 208. As
shutter 204 slides in groove 220, latch tab 226C (shown in FIG.
15B) also moves along groove 220. As shutter reaches the position
in which protective flap 224 covers window 232, latch tab 226C
makes contact with the cam surface 265 of hook 262. This is shown
in FIG. 27A. This causes latch 208 to flex slightly and forces hook
262 back into the window. As shown in FIG. 27B, when latch tab 226C
has passed by hook 262, latch 208 returns to its original
configuration and latch tab 226C is constrained in notch 263 by the
gripping surface 267 of hook 262. This locks shutter 204 in the
position in which window 232 is closed, protecting the data area
250 of optical disc 240 from damage.
[0107] FIG. 22 is a general view of cartridge 20 being inserted
into a cartridge tray 30 of a disc drive. FIGS. 23A-23C are
detailed views of an area 50 of cartridge tray 30.
[0108] FIG. 23A is a top view of area 50, showing the mechanism for
releasing shutter 204 as cartridge 20 is inserted into cartridge
tray 30. FIGS. 23B and 23C are perspective views of area 50.
Cartridge tray 30 includes a feature, in this embodiment a blade
302, that projects downward into shutter tracking groove 220. After
cartridge 20 has been inserted a short distance into cartridge tray
30, blade 302 comes into contact with leading edge 266 of release
cam 264 and forces release cam 264 and hook 262 back into the
window. See FIG. 28A. This releases latch tab 226C and frees
shutter 204 to slide along the edge of cartridge 20. See FIG. 28B.
Shortly thereafter, blade 302 abuts an edge 225 of shutter 204, and
at approximately the same time a spring-loaded shutter insert 304
of cartridge tray 30 engages opening 229 in the edge wall 228 of
shutter 204. As the user continues to slide cartridge 20 into
cartridge tray 30, blade 302 holds shutter 204 stationary, so that
shutter 204 slides along the edge of cartridge 20 to open window
232 of cover plate 202. When cartridge 20 has been fully inserted
into cartridge try 30, a feature (not shown) of the disc drive
engages recess 209 (FIG. 12C), holding cartridge 20 securely in
cartridge tray 30.
[0109] When the user wishes to remove cartridge 20 from the disc
drive, the user pushes a button on the disc drive which causes the
feature to retract from recess 209. A spring mechanism in the disc
drive forces cartridge 20 partially out of cartridge tray 30,
exposing the portion of cartridge adjacent trailing edge 218. As
the user manually removes cartridge 20 from cartridge tray 30,
shutter insert 304 remains in opening 229 of shutter 204 until
shutter 204 is fully closed and engaged by hook 262. Shutter insert
304 then lifts from opening 229 as the user continues to remove
cartridge 20 from the disc drive.
[0110] FIGS. 24-26 are cutaway views that show how a spindle motor
shaft 306 engages center hole 244 of disc assembly 206. FIG. 24 is
a view of cartridge 20 oriented as it would be during this process
with shell 200 removed. FIG. 25 is a similar view with disc
assembly 206 removed. FIG. 26 is a view from the underside of
cartridge 20 when cartridge has been fully loaded into a disc
drive.
[0111] As shown in FIG. 25, spindle motor shaft 306 contains an
annular clamp magnet 305, which is recessed from a protruding end
portion 309 of spindle motor shaft 306. Clamp magnet 305 can be
made of a permanent magnetic material such as NiFe or NiCrFe. As
shown in FIG. 24, when cartridge 20 is fully inserted into a disc
drive, spindle motor shaft 306 moves upward so as to insert
protruding end portion 309 into center hole 244. A tapered surface
307 on protruding end portion 309 helps to guide protruding end
portion 309 into center hole 244. Center hole 244 can have a
diameter of 4.010-4.022 mm and is tightly toleranced with respect
to protruding end portion 309. As protruding end portion 309 enters
center hole 244, clamp magnet 305 attracts or pulls down on
magnetic retainer ring 242 which, as described above, is glued onto
the non-data side of optical disc 240. Two alignment posts (not
shown) in the disc drive fit into alignment holes 222A and 222B to
assure that cartridge 20 is accurately and repeatably positioned in
the disc drive.
[0112] The embodiments of this invention described above are
illustrative and not limiting. Many alternative embodiments within
the broad scope of this invention will be apparent to those of
skill in the art.
* * * * *